Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/531—Electrode connections inside a battery casing
  • H01M50/533—Electrode connections inside a battery casing characterised by the shape of the leads or tabs
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/058—Construction or manufacture
  • H01M10/0585—Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
  • H01L23/00—Details of semiconductor or other solid state devices
  • H01L23/58—Structural electrical arrangements for semiconductor devices not otherwise provided for, e.g. in combination with batteries
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/04—Construction or manufacture in general
  • H01M10/0436—Small-sized flat cells or batteries for portable equipment
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/052—Li-accumulators
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/056—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
  • H01M10/0561—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of inorganic materials only
  • H01M10/0562—Solid materials
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/04—Processes of manufacture in general
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
  • H01M4/139—Processes of manufacture
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
  • H01M4/139—Processes of manufacture
  • H01M4/1391—Processes of manufacture of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/36—Selection of substances as active materials, active masses, active liquids
  • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M4/40—Alloys based on alkali metals
  • H01M4/405—Alloys based on lithium
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/36—Selection of substances as active materials, active masses, active liquids
  • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
  • H01M4/52—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
  • H01M4/525—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/531—Electrode connections inside a battery casing
  • H01M50/534—Electrode connections inside a battery casing characterised by the material of the leads or tabs
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/543—Terminals
  • H01M50/552—Terminals characterised by their shape
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/543—Terminals
  • H01M50/562—Terminals characterised by the material
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M6/00—Primary cells; Manufacture thereof
  • H01M6/40—Printed batteries, e.g. thin film batteries
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
  • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
  • H01L2924/0001—Technical content checked by a classifier
  • H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
  • H01M2004/028—Positive electrodes
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
  • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

• the field of this invention is the device, composition, method of depositing and fabrication of flexible solid-state, thin-film, secondary and primary electrochemical devices, including batteries, onto a semiconducting surface, onto a conductive or insulating surface of a semiconductor device, such as integrated circuit chips, or onto a circuit board, such as printed circuit board.
• Typical electrochemical devices comprise multiple electrically active layers such as an anode, cathode, electrolyte, substrate, current collectors, etc.
• Some layers such as, for example, an anode layer comprising lithium, are comprised of materials that are very environmentally sensitive.
• the substrate may, for example, not be a separate battery element but instead be provided by a semiconducting surface or onto a conductive or insulating packaging surface of a semiconductor device to which the battery is attached.
• Such batteries require an encapsulation to protect such environmentally sensitive material.
• Some schemes encapsulate the sensitive layers of electrochemical devices, such as encapsulation with gold foil.
• Other schemes encapsulate the device with pouch, for example, made of metal and plastic, that seals around the perimeter of the device.
• An exemplary embodiment of the present invention includes a battery fabricated on a semiconductor chip or fabricated on a flexible printed circuit board.
• the battery may, for example, include a first electrical contact, a bonding layer coupled with the first electrical contact and having a first embedded conductor, at least one battery cell structure in selective electrical contact with said first electrical contact via the first embedded conductor, a semiconducting surface or a conductive or insulating packaging surface of a semiconductor device.
• the bonding layer coupled with the semiconducting surface or a conductive or insulating packaging surface of a semiconductor device may have more than one conductor, such an optional, second embedded conductor, which in turn creates an optional, selective electrical contact of the semiconducting surface or a conductive or insulating packaging surface of a semiconductor device with said first electrical contact.
• the bonding layer and the at least one battery cell structure may be sandwiched between the first contact layer and the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device.
• the first electrical contact may, for example, include an encapsulate metal.
• the bonding layer may be an adhesive material, an insulating material, a plastic, a polymeric material, glass, and/or fiberglass.
• An insulative reinforcement layer may be embedded within the bonding layer. Such a reinforcement layer may be selectively conductive.
• the conductor may be, for example, a tab, a wire, a metal strip, a metal ribbon, multiple wires, multiple metal strips, multiple metal ribbons, a wire mesh, perforated metal, a metal coating applied to the adhesive layer, or a disk.
• the conductor may be woven within the bonding layer and the bonding layer may include a slit within which the embedded conductor is woven.
• the battery cell structure may include an anode, an electrolyte, a cathode, and a barrier layer.
• the cathode may, for example, not be annealed at all, annealed at lower temperatures, or annealed at higher temperatures, by using convection furnaces, rapid thermal anneal methods, or by a laser annealing and/or crystallization process.
• Another exemplary embodiment of the present invention includes a method of manufacturing a thin film battery comprising, in no particular order, the steps of creating a selectively conductive bonding layer, coupling the bonding layer with a first contact layer, coupling a first side of a battery cell structure with a semiconducting surface or a conductive or insulating surface of a semiconductor device or flexible printed circuit board, and coupling a second side of the battery cell structure with the bonding layer.
• the bonding layer may be made selectively conductive at an additional location at which the selectively conductive boding layer creates an electrical contact between the first contact layer and the semiconducting surface or a conductive or insulating surface of a semiconductor device or flexible printed circuit board.
• Yet another exemplary embodiment of the present invention includes a method of
• a thin film battery comprising, in no particular order, the steps of creating a selectively conductive bonding layer, coupling the bonding layer with a first contact layer, coupling a first side of a battery cell with the first contact layer as well, coupling the bonding layer with the a semiconducting surface or a conductive or insulating surface of a semiconductor device or flexible printed circuit board, and coupling a second side of the battery cell structure with the bonding layer.
• Examples of this embodiment may include creating a battery cell structure with an anode, cathode, and electrolyte layers, embedding at least one conductor within the bonding layer, weaving at least one conductive wire through the bonding layer wherein selective portions of the conductive wire are exposed, heating the bonding layer and compressing the conductor within the bonding layer, and insulating the battery with an insulating material.
• This exemplary embodiment may include providing an insulative reinforcement layer embedded within the bonding layer. The reinforcement layer may be selectively conductive.
• Yet another exemplary embodiment of the present invention involves a battery on a flexible printed circuit board wherein the first side of the battery cell structure is at least in direct mechanical contact with the flexible printed circuit board.
• the battery includes a first electrical contact, a bonding layer coupled with the first electrical contact and comprising ⁇ L ⁇ first embedded conductor, at least one battery cell structure in selective electrical contact with the first electrical contact via the first embedded conductor, the bonding layer coupled with the first electrical contact and comprising a second embedded conductor that is in selective electrical contact with the first electrical contact and the flexible printed circuit board.
• the bonding layer and the at least one battery cell structure are sandwiched between the first contact layer and a flexible printed circuit board.
• Another exemplary embodiment of the present invention involves a battery on a flexible printed circuit board wherein the battery cell structure is not in direct mechanical contact with the flexible printed circuit board but mechanically separated by at least the bonding layer.
• the battery includes a first electrical contact, a bonding layer coupled with the first electrical contact and comprising a first embedded conductor, at least one battery cell structure in selective electrical contact with the first electrical contact via said first embedded conductor, the bonding layer coupled with the flexible printed circuit board and having an optional, second embedded
• the bonding layer and the at least one battery cell structure are sandwiched between the first contact layer and a flexible printed circuit board.
• a method of manufacturing a thin film battery includes creating a selectively conductive bonding layer, coupling the bonding layer with a first contact layer, coupling a first side of a battery cell structure with a flexible printed circuit board; and coupling a second side of the battery cell structure with the bonding layer.
• a method of manufacturing a thin film battery includes creating a selectively conductive bonding layer, coupling the bonding layer with a first contact layer, coupling a first side of a battery cell structure with the first contact layer; and coupling a second side of the battery cell structure with the selectively conductive bonding layer, and coupling the bonding layer with the flexible printed circuit board.
• Another exemplary embodiment of the present invention includes the electrical connection between the battery cell and the semiconducting surface or the conductive packaging surface of a semiconductor device.
• the electrical connection between the battery cell and the semiconducting surface or the conductive packaging surface of a semiconductor device can be made by direct physical contact or by wire bonding.
• the battery prior to its integration onto the semiconducting surface or a conductive or insulating packaging surface of a semiconductor device or into or onto a flexible printed circuit board, the battery may be fabricated as a discrete device and then integrated as a whole together with its substrate and its encapsulation.
• Another embodiment of the present invention includes the electrical connection between a multi-battery cell stack and the semiconducting surface or the conductive packaging surface of a semiconductor device.
• FIG. IA shows a side view of an example of a thin film battery with a semiconducting surface or the conductive or insulating surface of a semiconductor device or a flexible printed circuit board according to an exemplary embodiment of the present invention.
• FIG. IB shows a side view of another example of a thin film battery with a semiconducting surface or the conductive or insulating packaging surface of a semiconductor device or a flexible printed circuit board according to an exemplary embodiment of the present invention.
• FIG. 2 shows a side view of an example of a thin film battery with a semiconducting surface or the conductive or insulating surface of a semiconductor device according to another exemplary embodiment of the present invention.
• FIG. 3A shows a side view of an exemplary thin film battery on a semiconducting surface or the conductive or insulating packaging surface of a semiconductor device or a flexible printed circuit board according to another exemplary embodiment of the present invention.
• FIG. 3B shows a side view of an exemplary thin film battery on a semiconducting surface or the conductive or insulating surface of a semiconductor device or flexible printed circuit board according to another exemplary embodiment of the present invention.
• FIG. 3C shows a top view of an exemplary thin film battery on a semiconducting surface or the conductive or insulating surface of a semiconductor device or flexible printed circuit board according to another exemplary embodiment of the present invention.
• FIG. 4A shows a side view of an exemplary thin film battery on a semiconducting surface or the conductive or insulating surface of a semiconductor device according to another exemplary embodiment of the present invention.
• FIG. 4B shows a side view of an exemplary thin film battery on a flexible printed circuit board according to another exemplary embodiment of the present invention.
• FIG. IA shows a side view of an electrochemical device according to one exemplary embodiment of the present invention.
• a first contact 101 is coupled with bonding layer 110 with a portion of the first contact 101 extending past the bonding layer 110.
• the bonding layer 110 may, for example, be bonded with the cell structure 115.
• a semiconducting surface or the conductive or insulating surface of a semiconductor device 105 is placed under the battery cell structure 115.
• An insulating surface of the semiconductor device 105 may be, for example, an insulating packaging surface of a semiconductor device or an upper
• a conductive surface may include, for example, a conductive contact pad, a conductive line, conductive via or other conductive layer formed on or at the device surface.
• a conductive surface also may be formed together with an insulating surface, such as a conductive surface formed on a packaging surface of a semiconductor device.
• Shown embedded within the bonding layer 110 is a first embedded conductor 120. This first embedded conductor 120, for example, creates a selectively conductive bonding layer.
• a selectively conductive bonding layer 110 permits conduction from the cell structure 115 through the bonding layer 110 to the first contact 101 at specific points, and yet provides insulation between the first contact 101 and the semiconducting surface or the conductive or insulating surface of a semiconductor device 105.
• Other types of battery cell structures may be also be included.
• the electrochemical device may have a second embedded conductor 121 that selectively creates an electrical contact between the first contact 101 and the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105.
• the semiconducting surface or the conductive or insulating surface of a semiconductor device 105 must be selectively insulating between the contacts points at which the first embedded conductor 120 and the second embedded conductor 121 meet the semiconducting surface or the conductive or insulating (e.g., packaging) surface of a semiconductor device 105.
• FIG. IB shows a side view of an electrochemical device according to an exemplary embodiment of the present invention.
• a first contact 101 is coupled with the battery cell structure 115.
• a bonding layer 110 is coupled to the battery cell structure 115 and a portion of the first contact 101, which extends past the bonding layer 110.
• a semiconducting surface or the conductive or insulating surface of a semiconductor device 105 is coupled with the bonding layer 110.
• Shown embedded within the bonding layer 110 is the first embedded conductor 120. This first embedded conductor 120, for example, creates a selectively conductive bonding layer.
• a selectively conductive bonding layer 110 permits conduction from the cell structure 115 through the bonding layer 110 to the semiconducting surface or the conductive or insulating (e.g., packaging) surface of a semiconductor device 105 at specific points, and yet provides insulation between the first contact 101 and the semiconducting surface or the conductive or insulating surface of a semiconductor device 105.
• 10575583 1 - 7 - device may have a second embedded conductor 121 that selectively creates an electrical contact between the first contact 101 and the semiconducting surface or the conductive or insulating surface of a semiconductor device 105.
• the semiconducting surface or the conductive or insulating surface of a semiconductor device 105 must be selectively insulating between the contact points at which the first embedded conductor 120 and the second embedded conductor 121 meet the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105.
• the first embedded conductor 120 and the second embedded conductor 121 may be placed within the bonding layer 110 in many different ways.
• a metal tab, a metal wire, a metal strip, a metal ribbon, multiple metal wires, multiple metal strips, multiple metal ribbons, a metal wire mesh, perforated metal foil, perforated metal, a metal coating applied to the adhesive layer, a metallic disk, a metallically coated fiberglass or combinations thereof may be used.
• the first embedded conductor 120 and the second embedded conductor 121 can provide electrical conduction between the cell structure 115 and the first contact 101 and the boding layer 110 provides insulation between the first contact 101 and the semiconducting surface or the conductive or insulating surface of a semiconductor device 105.
• the embedded conductors 120 and 121 may be woven within the bonding layer 110.
• the embedded conductors 120 and 121 may be, for example, disks embedded within the bonding layer 110. In some embodiments slits within the bonding layer 110 may be made in order to weave or place the embedded conductors 120 and 121 through the bonding layer 110. Also, for example, holes or other means may be used to place the embedded conductors 120 and 121 through the bonding layer 110.
• a reinforcement layer may be placed within the bonding layer.
• a fiberglass material may cover half of one surface of the bonding layer, woven through the layer and then cover the other half of the bonding layer.
• Such a layer of fiberglass without a conductive coating would insulate the materials placed between.
• the fiberglass may be coated in a localized area with a conductive material.
• Such conductive coatings can coat the fiberglass area in the top and bottom surface of the bonding layer.
• the fiberglass may conduct between the upper contact and the cell.
• Conductive material may be disposed on the fiberglass using ink jet, silk screen, plasma deposition, e-beam deposition, spray and/or brush methods. Other materials
• 10575583 1 - 8 - may be used rather than fiberglass, such as, for example, Kevlar", plastic, glass or other insulating materials.
• Another exemplary embodiment of the present invention may provide for selective contact between the first contact and the battery cell structure through holes in the bonding layer.
• holes in the bonding layer may allow the first contact and battery cell structure to remain in contact.
• the layers may be, for example, pressed together to create a contact.
• conductive glues or inks may be applied in or near the hole area in the bonding layer to make the contact between the layers. Lithium may also be used.
• the embedded conductors 120 and 121 and/or first contact may be made of gold, platinum, stainless steel, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper zirconium, niobium, molybdenum, hafnium, tantalum, tungsten, aluminum, indium, tin, silver, carbon, bronze, brass, beryllium, or oxides, nitrides, carbides, and alloys thereof.
• the first contact may be a metal foil, for example, may be made of stainless steel or any other metallic substance having the necessary or suitable characteristics and properties such as a requisite amount of conductivity.
• the metal foil may preferably comprise a solderable alloy, for instance, alloys of copper, nickel, or tin.
• the first contact may be, for example, less than 100 microns thick, less than 50 microns thick, or less than 25 microns thick.
• the electrochemical device 115 may include a cathode, anode and electrolyte.
• the cathode may comprise LiCoO 2
• the anode may comprise Lithium
• the electrolyte may comprise LIPON.
• Other electrochemical devices may be used as needed.
• the electrochemical device 115 may be coupled with the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105 in a number of ways.
• the electrochemical device for example, may be coupled with the semiconducting surface or the conducting or insulating surface of a semiconductor device 105 using glue.
• Glue as used in this application, extends to any material that may adhere the electrochemical device 115 to the semiconducting surface or the conducting or insulating surface of a semiconductor device 105.
• the glue may create either a mechanical or chemical bond between the two layers.
• Glue may also include chemically bonding the two layers without introducing another material or layer.
• Glue for example, may include but is not limited to
• the glue may be electrically conducting, semi-conducting, or insulating.
• the semiconducting surface or the conductive or insulating (e.g., packaging) surface of a semiconductor device 105 acts as a substrate for the battery.
• the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105 is provided and the electrochemical device 115 may be deposited thereon.
• the electrochemical device 115 may also be glued to the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105.
• a LiCoO 2 cathode layer is deposited on the semiconducting surface or the conducting or insulating surface of a semiconductor device 105.
• deposition techniques include, but are not limited to reactive or non-reactive RF magnetron sputtering, reactive or non-reactive pulsed DC magnetron sputtering, reactive or non-reactive DC diode sputtering, reactive or non-reactive thermal (resistive) evaporation, reactive or non-reactive electron beam evaporation, ion-beam assisted deposition, plasma enhanced chemical vapor deposition, or deposition methods, which may include, for example, spin coating, ink-jetting, thermal spray deposition, dip coating or the like.
• the cathode may be annealed using a thermal anneal such as anneal at lower temperatures, anneal at higher temperatures, or by using convection furnaces or rapid thermal anneal methods.
• a thermal anneal such as anneal at lower temperatures, anneal at higher temperatures, or by using convection furnaces or rapid thermal anneal methods.
• Another or an alternative post-deposition anneal may include laser annealing to improve the crystallization of the LiCoO 2 layer so as to fine-tune and optimize its chemical properties, such as its electrochemical potential, its energy, its power performance, and its reversible lattice parameters on electrochemical and thermal cycling.
• an electrolyte may be deposited on the cathode, followed by an anode. Again, these layers may be deposited by any of a number of processes common in the art.
• a bonding layer 110 may be placed between the electrochemical device and a first electrical contact 101.
• a metal encapsulate layer 101 may also be the first contact.
• a bonding layer 110 may be placed between the electrochemical device 115 and the semiconducting surface or the conducting or insulating surface of a semiconductor device 105.
• a metal encapsulate layer 101 may also be the first contact.
• the first contact may be a metal foil, for example, may be made of stainless steel or any other metallic substance having the necessary characteristics and properties such as a requisite amount of conductivity.
• the metal foil may preferably comprise a solderable alloy, for instance, alloys of copper, nickel, or tin.
• the first contact may be, for example, less than 100 microns thick, less than 50 microns thick, or less than 25 microns thick.
• the bonding layer 110 may include, for example, an adhesive material, an insulating material, polymeric material, glass, Kevlar ® , reinforcement materials, and fiberglass.
• the embedded conductors 120 and 121 may include, for example, a tab, a wire, a metal strip, a metal ribbon, multiple wires, multiple metal strips, multiple metal ribbons, a wire mesh, perforated metal, a metal coating applied to the adhesive layer, and a disk.
• FIG. 2 shows a second embodiment of a thin film battery on a chip.
• the battery may include a semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105, a cathode layer 145 deposited on the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105, an electrolyte 150, an anode 165, a modulating layer 160, an encapsulate 155, an anode current collector 170 and an insulator 175.
• the cathode 145 may comprise LiCoO 2
• the anode 160 may comprise Lithium
• the electrolyte 150 may comprise LIPON.
• Other electrochemical devices may be used as needed.
• the encapsulate 155 may comprise a ceramic-metal composite laminate of a multiple of alternating layers of Zirconium Nitride and Zirconium or Titanium Nitride and Titanium.
• the electrochemical device which may include the cathode 145, electrolyte 150 and anode 155, may be semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105 in a number of ways.
• the electrochemical device for example, may be coupled with the substantially conductive, semiconducting surface or the conductive packaging surface of a semiconductor device 105 using glue.
• Glue as used in this application, extends to any material that may adhere parts of the electrochemical device to
• the glue may create either a mechanical or chemical bond between the two layers. Glue may also include chemically bonding the two layers without introducing another material or layer.
• the glue may be electrically conductive in order to use the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105 as current collector. Glue, for example, may include but is not limited to electrically conductive cement glue and resin glue.
• the cathode 145 may also be deposited directly on the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105.
• a LiCoO 2 cathode layer is deposited on semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105.
• deposition techniques include, but are not limited to reactive or non-reactive RF magnetron sputtering, reactive or non-reactive pulsed DC magnetron sputtering, reactive or non- reactive DC diode sputtering, reactive or non-reactive thermal (resistive) evaporation, reactive or non-reactive electron beam evaporation, ion-beam assisted deposition, plasma enhanced chemical vapor deposition, deposition methods, which may include, for example, spin coating, ink-jetting, thermal spray deposition, dip coating or the like.
• a post-deposition laser anneal may be used to improve the crystallization of the cathode layer 145 in order to fine-tune and optimize its chemical properties, such as its electrochemical potential, its energy, its power performance, and its reversible lattice parameters on electrochemical and thermal cycling.
• chemical properties such as its electrochemical potential, its energy, its power performance, and its reversible lattice parameters on electrochemical and thermal cycling.
• the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device in the above embodiments may be part of any integrated circuit and may include, memory devices, processors or other logic circuits.
• Another embodiment of the present invention includes a battery deposited on a flexible printed circuit board including, for example, a first electrical contact; a bonding layer coupled with the first electrical contact and having an embedded conductor; at least one battery cell structure; and a flexible printed circuit board.
• 10575583 1 - 12 - cell structure may be sandwiched between the first contact layer and the flexible printed circuit board.
• the bonding layer may be selectively conductive through the embedded conductor.
• the battery cell structure may further be in selective electrical contact with the first electrical contact via the embedded conductor.
• FIG. 3A shows a side view of an electrochemical device according to another embodiment of the present invention.
• a first contact 301 is coupled with bonding layer 310 with a portion of the first contact 301 extending past the bonding layer 310.
• the bonding layer 310 may, for example, be bonded with the cell structure 315.
• a flexible printed circuit board 305 is placed under the battery cell structure 315. Shown embedded within the bonding layer 310 is a first embedded conductor 320. This first embedded conductor 320, for example, creates a selectively conductive bonding layer.
• a selectively conductive bonding layer 310 permits conduction from the cell structure 315 through the bonding layer 310 to the first contact 301 at specific points, and yet provides insulation between the first contact 301 and the flexible circuit board 305. Also shown embedded within the bonding layer 310 is the second embedded conductor 321. This second conductor, for example, further creates a selectively conductive bonding layer. The further selectively conductive boding layer 310 permits conduction from the flexible printed circuit board 305 through the bonding layer 310 to the first contact 301 at specific points, and yet provides insulation between the first contact 301 and the flexible printed circuit board 305. Other types of battery cell structures may be also be included.
• FIG. 3B shows a side view of an electrochemical device according to one exemplary embodiment of the present invention.
• a first contact 301 is coupled with the battery cell structure 315.
• a bonding layer 310 is coupled to the battery cell structure 315 and a portion of the first contact 301, which extends past the bonding layer 310.
• a flexible printed circuit board 305 is coupled with the bonding layer 310. Shown embedded within the bonding layer 310 is the first embedded conductor 320. This first embedded conductor 320, for example, creates a selectively conductive bonding layer.
• a selectively conductive bonding layer 310 permits conduction from the cell structure 315 through the bonding layer 310 to the flexible printed circuit board 305 at specific points, and yet provides insulation between the first contact 301 and the flexible printed circuit board 305.
• the electrochemical device may have a second embedded conductor 321 that selectively creates an
• the flexible printed circuit board 305 must be selectively insulating between the contacts points at which the first embedded conductor 320 and the second embedded conductor 321 meet the flexible printed circuit board 305.
• FIG. 3C is a top view of an exemplary electrochemical device integrated with a flexible circuit board 305, such as the exemplary devices described above with respect to FIGS. 3 A and 3B.
• conductive traces 330, 331 are formed on a surface of the circuit board 305.
• Other types of conductive surfaces, such as contact pads, wiring, exposed conductive vias etc., or combinations thereof may be provided on the circuit board surface to receive the electrochemical device.
• the first embedded conductor 320 is shown passing through bonding layer 310 to make electrical contact with conductive trace 330
• the second embedded conductor 321 is shown passing through bonding layer 310 to make electrical contact with conductive trace 331. It should be appreciated that an analogous arrangement can be achieved with respect to the examples including a semiconducting surface or the conductive or insulating packaging surface of a semiconductor device, as described above with respect to FIGS. IA and IB.
• the flexible circuit board 305 may comprise, for example, multiple circuit board layers with and without traces, single or double sided, semi-rigid, a film, and/or a polyimide film.
• the embedded conductors 320 and 321 may be placed within the bonding layer 310 in many different ways.
• a metal tab, a metal wire, a metal strip, a metal ribbon, multiple metal wires, multiple metal strips, multiple metal ribbons, a metal wire mesh, perforated metal foil, perforated metal, a metal coating applied to the adhesive layer, a metallic disk, a metallically coated fiberglass or combinations thereof may be used.
• the first embedded conductor 320 can provide selective electrical conduction between the cell structure 315 and the first contact 301 or the flexible printed circuit board 305, and yet provide insulation between the battery cell structure 315 and the first contact 301 or the flexible printed circuit board 305.
• the second embedded conductor 321 can provide selective electrical conduction between the first contact 301 and the flexible printed circuit board 305 and yet provide insulation between the first contact 301 and the flexible printed circuit board 305.
• the first embedded conductor 320 may be woven within
• the first embedded conductor 320 may be, for example, disks embedded within the bonding layer 310.
• slits within the bonding layer 310 may be made in order to weave or place the first embedded conductor 320 through the bonding layer 310.
• holes or other means may be used to place the first embedded conductor 320 through the bonding layer 310.
• the second embedded conductor 321 may be woven within the bonding layer 310.
• the second embedded conductor 321 may be, for example, disks embedded within the bonding layer 310.
• slits within the bonding layer 310 may be made in order to weave or place the second embedded conductor 321 through the bonding layer 310. Also, for example, holes or other means may be used to place the second embedded conductor 321 through the bonding layer 310.
• the electrochemical device 315 may include a cathode, anode and electrolyte.
• the cathode may comprise LiCoO 2
• the anode may comprise Lithium
• the electrolyte may comprise LIPON.
• Other electrochemical devices may be used as needed.
• the electrochemical device 315 may be coupled with the flexible printed circuit board 305 in a number of ways.
• the electrochemical device 315 may be coupled with the flexible printed circuit board 305 using glue.
• Glue as used in this application, extends to any material that may adhere the electrochemical device 315 to the flexible printed circuit board 305.
• the glue may create either a mechanical or chemical bond between the two layers.
• Glue may also include chemically bonding the two layers without introducing another material or layer.
• Glue for example, may include but is not limited to cement glue and resin glue.
• the glue may be electrically conducting, semi-conducting, or insulating.
• the electrochemical device 315 may be coupled with the first electrical contact 301 in a number of ways.
• the electrochemical device 315 may be coupled with the first electrical contact 301 using glue.
• Glue as used in this application, extends to any material that may adhere the electrochemical device 315 to the first electrical contact 301.
• the glue may create either a mechanical or chemical bond between the two layers.
• Glue may also include chemically bonding the two layers without introducing another material or layer.
• Glue for example, may include but is not limited to cement glue and resin glue.
• the glue may be electrically conducting, semi-conducting, or insulating.
• the flexible printed circuit board 305 acts as a substrate for the battery, which may be deposited thereon.
• the first electrical contact 301 acts as a substrate for the battery, which may be deposited thereon.
• the flexible printed circuit board 305 acts as an encapsulate for the battery.
• the first electrical contact 301 acts as an encapsulate for the battery.
• a thin film battery is provided on a semiconducting surface or the conductive or insulating surface of a semiconductor device with a barrier layer therebetween.
• Elements depicted in Figure 4A like those above in FIG. IA are shown having the same reference numbers.
• a first contact 101 is coupled with bonding layer 110 with a portion of the first contact 101 extending past the bonding layer 110.
• the bonding layer 110 may, for example, be bonded with the cell structure 115.
• a semiconducting surface or the conductive or insulating (e.g., packaging) surface of a semiconductor device 105 with a barrier layer 107 is placed under the battery cell structure 115.
• barrier layer 107 may include, for example, titanium nitride.
• the barrier layer 107 may also comprise a semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105.
• a conductive surface may include, for example, a conductive contact pad, a conductive line, conductive via or other conductive layer formed on or at the device surface.
• a conductive surface also may be formed together with an insulating surface, such as a conductive surface formed on a packaging surface of a semiconductor device.
• An insulating surface of the semiconductor device 105 may be, for example, an insulating packaging surface of a semiconductor device or an upper insulating surface the semiconductor device. Shown embedded within the bonding layer 110 is conductor 120.
• This conductor 120 creates a selectively conductive bonding layer.
• a selectively conductive bonding layer 110 permits conduction from the cell structure 115 through the bonding layer 110 to the first contact 101 at specific points, and yet provides insulation between the first contact 101 and the barrier layer 107.
• Other types of battery cell structures may be also be included.
• the electrochemical device 115 may be coupled with the semiconducting surface or the conductive or insulating (e.g., packaging) surface of a semiconductor device 105 and barrier layer 107 in a number of ways.
• the electrochemical device for example, may be coupled with the barrier layer using glue.
• Glue as used in this application, extends to any material that may adhere the electrochemical device 115 to the barrier layer 107.
• the glue may create either a mechanical or chemical bond between the two layers.
• Glue may also include chemically bonding the two layers without introducing another material or layer.
• Glue for example, may include but is not limited to cement glue and resin glue.
• the glue may be electrically conducting, semi-conducting, or insulating.
• the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105 acts as a substrate for the battery.
• the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105 is provided and the barrier layer 107 may be deposited thereon.
• the barrier layer 107 may also be glued to the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 105.
• the electrochemical device 115 may be deposited directly on the barrier layer 107.
• a LiCoO 2 cathode layer is deposited on the barrier layer 107 by way of methods described above.
• a thin film battery is provided on a flexible circuit board. Elements depicted in Figure 4B like those above in FIG. 3A are shown having the same reference numbers.
• a first contact 301 is coupled with bonding layer 310 with a portion of the first contact 301 extending past the bonding layer 310.
• the bonding layer 310 may, for example, be bonded with the cell structure 315.
• a flexible printed circuit board 305, such as described above, and a barrier layer 307 is placed under the battery cell structure 315.
• the barrier layer 307 may, for example, include titanium nitride.
• Shown embedded within the bonding layer 310 is conductor 320. This conductor 320, for example, creates a selectively conductive bonding layer.
• a selectively conductive bonding layer 310 permits conduction from the cell structure 315 through the bonding layer 310 to the first contact 301 at specific points, and yet provides insulation between
• the conductor 320 may be provided within the bonding layer 310 as described above. In each of these examples, the conductor 320 can provide electrical conduction between the cell structure 315 and the first contact 301 and yet provide insulation between the first contact 301 and the barrier layer 307.
• the electrochemical device 315 may be coupled with the semiconducting surface or the conductive or insulating packaging surface of a semiconductor device 305 and barrier layer 307 in a number of ways.
• the electrochemical device for example, may be coupled with the barrier layer using glue.
• Glue as used in this application, extends to any material that may adhere the electrochemical device 315 to the barrier layer 307.
• the glue may create either a mechanical or chemical bond between the two layers.
• Glue may also include chemically bonding the two layers without introducing another material or layer.
• Glue for example, may include but is not limited to cement glue and resin glue.
• the glue may be electrically conducting, semi-conducting, or insulating.
• the flexible printed circuit board 305 acts as a substrate for the battery and the barrier layer 307 may be deposited thereon.
• the barrier layer 307 may also be glued to the flexible printed circuit board 305.
• the electrochemical device 315 may be deposited directly on the barrier layer 307.
• FIGS. 4A and 4B show only one conductor 120, 320, respectively, it is to be understood that exemplary embodiments also may include at least one second conductor, such as conductors 121, 321, respectively described above in connection with FIGS. IA and 3A. Further, electrical connection between the first contact 101, 301 and the underlying semiconducting surface, conductive or insulating surface of a semiconductor device, or a flexible circuit board can be made by conductors 121, 321 through the bonding and/or barrier layers.
• the above-discussed exemplary embodiments may also include multiple electrochemical devices stacked upon a semiconducting surface or the conductive or insulating (e.g., packaging) surface of a semiconductor device.
• the above-discussed exemplary embodiments may also include multiple electrochemical devices stacked upon the first electrical contact 301.
• the present exemplary embodiments provide alternative schemes to encapsulate the chemically and mechanically sensitive layers of electrochemical devices, which are less expensive than prior encapsulation schemes using gold foil.
• the above exemplary embodiments also avoid problems of other prior schemes relating to blow out of the seals of a metal and plastic pouch encapsulating an electrochemical device resulting from temperature changes, which cause the gas within the metal and plastic pouch to expand and/or contract.
• the exemplary embodiments described herein also provide a rechargeable secondary battery directly fabricated on a semiconductor device such as an integrated circuit. Such batteries provide power during times when the circuit is powered off and are quickly and easily recharged when power resumes. Critical circuitry may benefit from localized power provided by such batteries.
• the exemplary embodiments also provide for less expensive and more reliable encapsulating approaches, and better approaches to providing electrically conductive contacts, including encapsulation that is substantially thinner than known encapsulation methods.
• the exemplary embodiments also provide flexible integrated circuits and/or flexible printed circuit boards with thin film flexible batteries coupled thereon.
• a conductive material provided in an opening in the bonding layer, such as the slit
• electrical contact between the battery cell structure 115, 315 and first electrical contact 101, 301 may be provided by a number of other ways.
• embedding a conductive powder within an adhesive forming the bonding layer 110, 310 may provide electrical conduction between the cell structure 115, 315 and the first contact 101, 301.
• a conductive powder such as a metallic powder (e.g., nickel powder) can be embedded in an adhesive bonding layer 110, 310 at one or more selected areas within an adhesive bonding layer 110, 310 and between the contact 101, 301 and the battery cell structure 115, 315.
• the electrochemical device may comprise a discrete device (e.g., fully packaged with its own substrate and own encapsulation) on a semiconductor surface, a conducting or insulating surface of a semiconductor device or a flexible printed circuit board.
• a discrete device e.g., fully packaged with its own substrate and own encapsulation
• the electrochemical device may be fabricated as a discrete device, and then integrated as a whole together with its substrate and its encapsulation.

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